Automatically deployable energy efficient mobile structure

ABSTRACT

Deployment shelter systems and methods of articulation thereof are disclosed.

The present application claims priority to U.S. Provisional Patent Application Ser. No. 61/799,150, filed on Mar. 15, 2013, U.S. Provisional Patent Application No. 61/704,278, filed on Sep. 21, 2012, and U.S. Provisional Patent Application No. 61/644,960, filed on May 9, 2012, each of which is incorporated herein in its entirety by reference.

BACKGROUND

Deployable structures may be useful in many applications as they may provide a compact storage configuration and larger useful area deployed configuration. The present invention provides a novel structure and method for deploying a structure.

SUMMARY OF THE INVENTION

The present invention may be better understood by reference to the description and figures that follow. It is to be understood that the invention is not limited in its application to the specific details as set forth in the following description and figures. The invention is capable of other embodiments and of being practiced or carried out in various ways.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present invention are better understood when the following detailed description is read with reference to the accompanying drawings, wherein:

FIG. 1A is a perspective view of an embodiment of a shelter system in the stowed configuration of the current invention;

FIG. 1B is a perspective view of the embodiment of a shelter system of FIG. 1A as shown partially deployed;

FIG. 1C is a perspective view of the embodiment of a shelter system of FIG. 1A as shown partially deployed;

FIG. 1D is a perspective view of the embodiment of a shelter system of FIG. 1A as shown partially deployed;

FIG. 1E is a perspective view of the embodiment of a shelter system of FIG. 1A as shown fully deployed;

FIG. 2 is an isolated view of an embodiment of the frame of the structure shown in FIG. 1A;

FIG. 3 is an isolated, partial perspective view of an alternative embodiment of a frame of the structure shown in FIG. 1A;

FIG. 4 is a schematic view of an embodiment of deployable frame members in a stored or stowed configuration of a structure of the present invention; and

FIG. 5 is a view of an embodiment of a controller of the present invention.

Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Reference will now be made in detail to various embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation, not limitation, of the invention. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope and spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

As used herein, reference characters with the same two ending digits as other reference characters to indicate structure in the present specification and drawings, without a specific discussion of such structure, is intended to represent the same or analogous structure in different embodiments. For example, and as further seen herein, the structures indicated by reference characters 102 and 202 both indicate a frame in different embodiments of the present invention.

The present invention includes deployable structures that may readily transition between a stored configuration and a deployed configuration. FIGS. 1A-1E show an exemplary embodiment of a deployable structure of the present invention in various stages between a stored configuration, shown in FIG. 1A, and a fully deployed configuration, shown in FIG. 1E. As shown in FIGS. 1A-1E, structure 100 includes roof panel 120, bottom panel 122 (not shown), side panels 124, and end panels 126 (only one shown). In some embodiments, any depicted panel may be replaced with multiple adjacent panels. In one embodiment, roof panel 120 is a unitary panel that spans the entire top or roof of structure 100 when in the stored configuration shown in FIG. 1A. In some embodiments, roof panel 120 may remain stationary during deployment and retraction of the structure between its deployed and stored positions. In addition, bottom panel 122 may be located on the exterior side of the bottom frame members 106 and/or on the interior side of bottom frame members 106. When bottom panel 122 is located on the interior side of bottom frame members 106, bottom panel 122 may form a floor for the structure.

Structure 100 also includes door 118. In some embodiments, additional doors or alternative locations for one or more doors may be employed. Alternative types of doors are also within the scope of the present invention, such as double doors, garage doors, and rolling doors. Other openings, such as windows and hatches, may also be included in other embodiments.

Structure 100 also includes frame 101 having top frame members 102, bottom frame members 104, and vertical frame members 108, which are each shown in isolation in FIG. 2. As shown in the exemplary embodiments, frame 101 also includes deployable frame members, including deployable roof frame members 110, deployable side frame members 112, and deployable floor frame members 114.

In addition, FIG. 3 illustrates an exemplary and detailed embodiment of frame 101 having top frame members 102, bottom frame members 104, vertical frame members 108, deployable roof frame members 110, deployable side frame members 112, and deployable floor frame members 114. As shown, vertical frame members 108 may be present in various locations between top frame members 102 and bottom frame members 104 and are not limited to the corners of the unit as alternatively shown in FIG. 2. In addition, frame 101 includes top frame support members 102′, 102″, and 102′″, which are located interior of top frame members 102. In other embodiments, additional structures or shapes may be used for the optional top frame support members, and some embodiments may include more or less top frame support members than shown in FIG. 3. Frame 101 also includes bottom frame support members 104′, wherein some bottom frame support members 104′ form a grid or waffle pattern in the depicted embodiment.

Frame members and deployable frame members may be comprised of any suitable material. In some embodiments, frame members and deployable frame members may be comprised of the same or different materials. In addition, some frame members may be of a different material from other frame members, and likewise amongst deployable frame members.

One of ordinary skill in the art will readily appreciate that the depicted embodiment is exemplary and that alternative frame structures and arrangements are within the scope of the present invention. In some alternative embodiments, the frame may be formed with more or less frame members or deployable frame members and/or with alternative and/or additional placements of frame members and deployable frame members. In some embodiments, a single structure may serve as two members, such as a single beam serving as both a deployable floor frame member and a deployable side frame member. In some embodiments of the present invention, a frame may have one, two, three, four, or more top frame members; one, two, three, four, or more bottom frame members; one, two, three, four, or more transverse frame members; and/or one, two, three, four, or more vertical frame members. For example, additional top frame members may be arranged between the frame top frame members 102 shown in FIG. 1. In similar fashion, additional bottom frame members, transverse frame members, and/or vertical frame members may be disposed between the respectively depicted frame members in FIG. 1.

Embodiments of the present invention may also include deployable panels. As shown in FIG. 1E, structure 100 includes deployable roof panels 130 (which is also the same as side panel 124, but is represented with different reference numerals for clarity), and deployable floor panels 132, which are shown as two panels that are hinged together to form a bifolding panel, deployable side panels 134, and deployable end panels 136. In some embodiments, some or all of the deployable panels may be mounted or affixed to deployable frame members, such as deployable roof frame members 110, deployable side frame members 112, and deployable floor frame members 114. In some embodiments, deployable frame members may be affixed to or connected with deployable panels at various locations, such as at or near the edge of a panel or offset within the edge of a deployable panel.

In the depicted embodiment shown in FIGS. 1A-1E and FIG. 2, deployable roof panels are shown mounted on deployable roof frame members 110, which are hingedly attached to top frame member 102, deployable end panels 134 are mounted on deployable side frame members 108, and deployable floor panels are hingedly attached to bottom frame member 104. In addition, with reference to the depicted embodiment, deployable side frame members 134 are hingedly attached to deployable floor frame members 114. As shown, deployable side panels 134 are not connected or hinged to deployable roof frame members 110 or deployable roof panels 130 in the stored configuration. Deployable side frame members 108 are hingedly connected to deployable floor frame members in the embodiment shown in FIG. 1A-1E.

In other embodiments, some or all deployable panels may be attached, connected, or hinged directly to one or more of frame members 102, bottom frame members 104, and/or vertical frame members 108 without being affixed to any deployable frame members. In some embodiments, some or all of the depicted deployable frame members may be omitted. In still other embodiments, deployable frame members may take alternative constructions. For example, deployable roof panels 130 are shown in FIG. 1 as joined to four deployable roof frame members 110. However, in other embodiments, more or fewer deployable roof frame members 110 may be employed. For example, in some embodiments deployable roof panel 130 may be mounted on two deployable roof frame members positioned along the shorter depicted edges of deployable roof panel 130. In still other embodiments, deployable roof panel 130 could be mounted on three deployable roof frame members 110, wherein the edge of deployable roof panel 130 nearest to top frame member 102 does not include a deployable roof frame member. Such alternative embodiments are equally available for all other deployable frame members.

In some embodiments, one or more panels may be omitted or of smaller dimensions. For example, if an open or partially-open configuration is preferred after the unit is deployed, one or both deployable side panels and/or deployable end panels may be omitted. Alternatively, one or more of deployable side panels and/or deployable end panels could be configured to only extend partially between a deployable floor panel and a deployable roof panel, such as to leave a partial opening upon deployment, such as for a window frequently observed at concession stands.

The panels of the present invention may be composed of any suitable material for the intended use of the structure. In some embodiments, the panels will be metal, such as aluminum. In one embodiment, an aluminum skin of about 0.125″ thickness or other embodiment using a composite material such as available from 3A Composites USA under the brand name Dibond® may be employed. Some or all panels (such as interior floor panels) may include a durable finish, such as a non-skid coating available from TUFF Coat Manufacturing, Inc. of Montrose, Colo. In one embodiment, an interior side of a bottom panel may be coated with a non-skid coating.

In some embodiments, sealant may be provided at hinged areas or been any gaps between panels. Such sealant may include rubber stripping or any other suitably flexible or pliable material. Any suitable sealant may be applied on the interior of the shelter, on the exterior of the shelter, or both. By way of example, sealant may be provided between or around the position at which deployable roof panel 130 meets top frame member 102, at which deployable floor panels 132 meets bottom frame member 104, at which deployable side panels 134 meet deployable floor panels 132, and/or at other locations at which components meet or articulate.

As shown in FIGS. 1B-D, structure 100 includes roof actuators 140, which may be attached to deployable frame roof panels 130 and/or deployable roof frame members 110. In some embodiments, roof actuators may be 4,000 lb. electrohydraulic actuators, such as actuators available from HydraMotion of Cleveland, Ohio under the name F4000. As shown in FIGS. 1C-1D, structure 100 may also include side actuator 142, which in some embodiments may be automated and powered by electrohydraulic actuation. In some embodiments, one or more side actuator 142, such as an electrohydraulic actuator, may be positioned on each side of the structure to deploy deployable side panel 134. As shown in the exemplary embodiment in FIGS. 1C and 1D, the side actuator is shown as a scissor arm. In some embodiments, side actuator 142 may be connected to deployable side panel 134 and vertical frame member 108. The depicted system and components for articulating or moving the deployment panels are exemplary of a single embodiment, and it will be readily apparent to one of ordinary skill in the art that alternative types of components may be used within the scope of the present invention.

One of ordinary skill in the art will appreciate that the depicted actuators are exemplary in nature and that alternative lifting members, such as electrical, mechanical and pneumatic actuators, may be employed. In addition, alternative quantities and placements of actuators are within the scope of the present invention. By way of example, an actuator may attach to deployable roof frame members in a track such that the actuator moves outwardly in the track as the unit is deployed. In some embodiments, actuators may be omitted, such as in structures designed for manual operation, and a locking mechanism may be included to hold the deployable panels in place after manual deployment.

Structures of the present invention may be shaped in any manner suitable for its intended purpose. In some embodiments, the stored configuration of the inventive structure is in accordance with standards set by the International Organization for Standardization (“ISO”) for cargo and shipping containers, including ISO 1C, which is incorporated herein in its entirety by reference. In one embodiment, the structure may have a generally rectangular shape in its stored configuration. In other embodiments, the inventive unit may have one or more of the following parameters: 8′×8′×19′10.5″ dimensions in stored configuration, about 400 square feet of interior space in its deployed configuration, and a tare weight of 10,000 pounds or less. Structures of the present invention may also include slots 144 located on their bottom to accommodate the forks of a forklift. In addition, structures of the present invention may have legs, which may be optionally retractable or attachable to the structure, to elevate the structure above the ground, such as legs 145 shown in FIG. 1A.

In operation, structure 100 may be configured to transition between a stored configuration (such as shown in FIG. 1A) and a deployed configuration (such as shown in FIG. E). When in the storage configuration, some or all of the deployable panels may be contained within the unit. Also, in the stored position, as shown in FIG. 1A and schematically in FIG. 4 (in which the circles represent hinged connections), deployable roof panels 130 form exterior sides of the structure, and deployable side panel 134 is adjacent to each deployable roof panel 130. Also, deployable floor panel 132, which is shown in the exemplary embodiment as a bifolding panel (or two hingedly joined panels) is interiorly adjacent to deployable side panel 134, and deployable end panel 136 is interiorly adjacent to deployable floor panel 132. This exemplary configuration may occupy minimal interior of structure 100 in the stored position, such that structure 100 may be used for storage.

With reference to FIGS. 1A-1E, an exemplary deployment of one side of structure 100 is illustrated. Upon activation of deployment, deployable roof panel 130 is rotated about a hinge to its deployed state. Subsequently, deployable side panel 134 is deployed by side actuator 142 and, in the depicted embodiment, deployable floor panel 132 is hingedly connected to deployable side panel 134 and is also deployed. In some embodiments, deployable side panel 134 may not be deployed until deployable roof panel 130 is fully deployed, whereas in other embodiments deployable side panel 134 may begin deploying prior to deployable roof panel 130 being fully deployed. In some embodiments, deployable roof panel 130 may be deployed to be generally parallel with the ground surface upon which structure 100 rests. In other embodiments, deployable roof panel 130 may rest at a downward angle when fully deployed, which may assist with water runoff.

Upon complete deployment of deployable side panels 134 and deployable floor panel 132, deployable end panel 136 may be deployed. In the depicted embodiment, deployable end panel 136 is manually articulated about a hinge for deployment, but in other embodiments such deployment may be automated, such as by an actuator or mechanical means. In still other embodiments, deployable end panels 134 may also or alternatively include an accordion or panache-type of panel that may be unfolded manually or automatically upon deployment. In still other embodiments, deployable end panels 134 may also or alternatively include a flexible material, such as a rubber or cloth material, that is connected to deployable side walls and deployed therewith. To return a unit to its stored configuration, the deployment order is merely reversed.

The embodiment in FIGS. 1A-1E is illustrated as deploying a deployable roof panel, a deployable side panel, a deployable floor panel, and a deployable wall panel on one side of the structure and then subsequently deploying those panels on the opposing side of the structure. However, in other embodiments, each correlating deployable panel may be deployed substantially simultaneously on each side of the structure. In still other embodiments, an operator may be able to selectively control such deployments to deploy one side or both sides, either concurrently or consecutively.

Structures of the present invention may be manually deployed, automatically deployed, or deployed using a combination of manual and automated deployment. By way of example, system 100 in FIGS. 1A-1E includes both automatic and manual deployment. In particular, deployable roof panels 130, deployable side panels 134, and deployable floor panels 132 are automatically deployed using electrohydraulic actuators as discussed above, whereas deployable end panels 136 are manually deployed by manually rotating the deployable wall panels about a hinge. In other embodiments, articulation of a unit may be entirely automatic or entirely manual.

As indicated above, and by way of example and without limiting the present invention, automated deployment may be carried out using electrohydraulic actuators. In one embodiment, a control panel 150 having buttons A, B, C, and D, such as shown in FIG. 5, may be used to initiate deployment or retraction of a structure of the present invention. In some embodiments, control panel 150 may be a control unit mounted on the interior or exterior of the structure. In other embodiments, control panel 150 may be a remote control device.

In other embodiments, a phone, cellular phone, or smart phone device may be used as a control panel and may be in communication with the structure through cellular or network signals or connections. As used herein, the reference “in communication with” indicates that data and/or signals are transferrable between the referenced components, and include both physical connections and wireless connections. In addition, “in communication with” also includes embodiments in which the referenced components are in direct connection (i.e., directly connected to each other with a cable) as well as indirect connections, such as when data is transmitted through an intermediate component and either relayed in the same format or converted and then relayed to the referenced component. In other embodiments, some or all of the aforementioned probes may be in communication with a single probe processor. In some embodiments, a security code may be necessary to operate control panel 150 or any other device controlling structure 100.

As shown in the exemplary embodiment in FIG. 5, button A may be depressed to activate deployment of the unit. Upon depression of button A, the following deployment may occur:

-   -   1. An electrical signal is sent to one or more roof actuators         140, which initiates roof actuator and results in deployment of         one or more deployable roof panels 130.     -   2. Upon partial or complete deployment of deployable roof panel         130, an electrical signal is sent to side actuator 142, which         results in deployment of one or more deployable side panels 134         and connected deployable floor panel 132.     -   3. Upon complete deployment of deployment of deployable side         panel 134 and deployable floor panel 132, deployable end panel         136 may be manually rotated on its hinge as shown between FIGS.         1C and 1D. In alternative embodiments, this step may also be         automatically actuated.

In some embodiments, the foregoing steps may be controlled by separate control buttons. In some embodiments, individual buttons on a control panel may operate individual steps in the deployment process. For example, one button on a control panel may activate step 1 above and another button may activate step 2 above. Similarly, buttons may be limited to controlling the deployment for only one side of a structure. In addition, certain buttons on a control panel may be dedicated to retracting some or all deployable panels to the stored configuration. In some embodiments, a manual or automatic locking mechanism, such as a pin that locks the some or all components in place, may be present to secure the structure in a deployment configuration. In some embodiments, a structure may be articulated from a deployment configuration to a stored configuration by performing the deployment process in reverse order.

Additional features may also be optionally incorporated into structures of the present invention. Such features may include, without limitation, one or more of interior lighting (such as recessed light emitting diodes), interior electrical receptacles in the floor and/or some or all of the panels, audible and/or visual warning signals to indicate deployment or retraction of the structure, insulation or materials to provide an R-value of about 14 or greater, and heating and/or air conditioning units (HVAC) also known as environmental control units (ECU). Some embodiments may also include battery power units, generators, and/or ports for receiving power from external sources. Some units may have storage containers for gasoline or other fuel sources. Still other units may include solar panels for powering the unit. In some embodiments, the solar panels may be attached to a deployable panel in order to provide protection while in a stored configuration.

The foregoing description of illustrative embodiments and uses of the invention have been presented only for the purpose of illustration and description and is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Numerous modifications and adaptations thereof will be apparent to those of ordinary skill in the art without departing from the scope of the present invention. As such, further modifications and equivalents of the invention herein disclosed may occur to persons skilled in the art using no more than routine experimentation, and all such modifications and equivalents are believed to be within the spirit and scope of the invention as described herein. 

What is claimed is:
 1. A deployable structure comprising: at least one roof panel, at least one bottom panel that is generally parallel to the at least one roof panel, at least two end panels that join the at least one roof panel and at least one bottom panel, at least one deployable roof panel that forms a side wall when the structure is in a stored position, at least one deployable side panel that is adjacent to the at least one deployable roof panel when the structure is in the stored configuration, at least one deployable floor panel that is adjacent to the at least one deployable side panel when the structure is in the stored configuration, wherein the at least one deployable floor panel is hingedly attached to the structure in order to rotate to a deployed floor position and wherein the at least one deployable side panel is hingedly attached to the deployable floor panel in order to rotate do a deployed side wall position, wherein the deployable roof panel is hingedly attached to the structure in order to rotate to a deployed roof position,
 2. The deployable structure of claim 1 further comprising: a frame comprising at least four top frame members, at least four bottom frame members positioned in a plane that is generally parallel to the top frame members, and at least four vertical members that join the top frame members and the bottom frame members, wherein the at least one roof panel is affixed to the top frame members, and wherein the at least one bottom panel is affixed to the bottom frame members.
 3. The deployable structure of claim 2 further comprising one or more deployable roof frame members hingedly attached to a top frame member, one or more deployable floor frame members hingedly attached to a bottom frame member, and one or more deployable side frame members 108 hingedly attached to a deployable floor frame member.
 4. The deployable structure of claim 3 wherein one or more deployable roof panels are affixed to one or more deployable roof frame members and one or more deployable floor panels are affixed to one or more deployable floor frame members, and one or more deployable side panels are affixed to one or more deployable side frame members.
 5. The deployable structure of claim 1 further comprising a first deployable end wall that is adjacent to the at least one deployable floor panel when the structure is in the stored configuration.
 6. The deployable structure of claim 3 further comprising a second deployable end wall that is adjacent to the first deployable end wall that when the structure is in the stored configuration.
 7. The deployable structure of claim 5 further comprising at least one roof actuator positioned and configured to deploy a deployable roof panel to a deployed configuration.
 8. The deployable structure of claim 7 further comprising at least one side actuator positioned and configured to deploy a deployable side panel to a deployed configuration.
 9. The deployable structure of claim 8 further comprising a remote control to control the transition of the deployable structure between a stored configuration and a deployed configuration.
 10. A method for deploying a structure, the method comprising: articulating a deployable roof from a stored configuration to a deployed configuration, and articulating a deployable side wall from a stored configuration, wherein a deployable floor is connected to and deployed in connection with the deployment of the deployable side wall, wherein articulation of the deployable roof is commenced prior to the articulation of the deployable side wall.
 11. The method of claim 10 further comprising articulating one or more deployable end walls from a stored configuration to a deployed configuration after deployment of the deployable side wall.
 12. A method for deploying a structure, the method comprising the following steps in the order recited: articulating deployable roof from a stored configuration to a deployed configuration, and articulating a deployable side wall from a stored configuration, wherein a deployable floor is connected to and deployed in connection with the deployment of the deployable side wall, wherein articulation of the deployable roof is commenced prior to the articulation of the deployable side wall.
 13. The deployable structure of claim 5 wherein a deployable floor panel is comprised of two hingedly adjoined panels that form a bifolding deployable floor panel. 